Patent application title: SYSTEMS, METHODS AND APPARATUS FOR USE IN DISTRIBUTING IRRITANT POWDER

Abstract:

The present embodiments provide apparatuses for use in launching an
inhibiting powder. These embodiments comprise a source of impulse
pressure that induces a propellant pressure, a barrel cooperated with the
source of impulse pressure to receive the propellant pressure, inhibiting
powder positioned within an interior of the barrel, a burst diaphragm
secured between the source of the impulse pressure and the inhibiting
powder, and an actuator that activates the source of impulse pressure to
deliver an expanding gas producing an increasing pressure that is applied
to the burst diaphragm where the burst diaphragm bursts when the applied
pressure exceeding a burst threshold, resulting in a release of the
propellant pressure into the barrel to drive the inhibiting powder from
the barrel in substantially an aerosol form generating a cloud of
inhibiting powder.

Claims:

1. An apparatus for use in launching an inhibiting powder, the apparatus
comprising:a source of impulse pressure that induces a propellant
pressure;a barrel cooperated with the source of impulse pressure to
receive the propellant pressure;inhibiting powder positioned within the
barrel;a burst diaphragm secured between the source of the impulse
pressure and the inhibiting powder; andan actuator that activates the
source of impulse pressure to deliver an expanding gas producing an
increasing pressure that is applied to the burst diaphragm where the
burst diaphragm bursts when the applied increasing pressure exceeding a
burst threshold of the burst diaphragm, where the bursting of the burst
diaphragm results in a release of the propellant pressure into the barrel
to drive the inhibiting powder from the barrel in substantially an
aerosol form generating a cloud of inhibiting powder extending from a
exit end of the barrel and out a distance from the exit end of the
barrel.

2. The apparatus of claim 1, wherein the inhibiting powder is positioned
within the barrel such that the inhibiting powder is in contact with an
interior surface of the barrel prior to the propellant pressure being
delivered into the barrel, and the inhibiting powder continues to contact
the interior surface of the barrel as the inhibiting powder travels along
a portion of a length of the barrel to the exit end of the barrel to be
propelled out of the exit end of the barrel.

3. The apparatus of claim 1, further comprising:an expansion chamber
adjacent the burst diaphragm and positioned between the burst diaphragm
and the source of the impulse pressure such that upon the activation the
source of the impulse pressure delivers the gas to the expansion chamber
such that the gas within the expansion chamber applies the increasing
pressure to the burst diaphragm to burst the burst diaphragm releasing
the compressed gas from the expansion chamber into the barrel to drive
the inhibiting powder from the barrel.

4. The apparatus of claim 3, wherein the source of impulse pressure
comprises:a compressed gas cartridge storing compressed gas;a puncture
pin positioned relative to the compressed gas cartridge; andthe expansion
chamber positioned relative to the puncture pin;where the burst diaphragm
is positioned between the expansion chamber and the inhibiting powder,
such that upon activation one of the puncture pin and compressed gas
cartridge is moved relative to the other such that the puncture pin
punctures the compressed gas cartridge releasing the compressed gas into
the expansion chamber resulting in the increasing pressure applied to the
burst diaphragm to burst the burst diaphragm releasing the compressed gas
to expel the loose inhibiting powder from the barrel.

5. The apparatus of claim 3, further comprising:a frame comprising the
actuator; anda barrel assembly comprising the barrel, burst diaphragm,
and expansion chamber, where the barrel assembly is detachably secured
with the frame.

6. The apparatus of claim 5, wherein the cloud, generated upon propelling
the loose inhibiting powder from the exit end of the barrel, extends out
a distance, from the exit end of the barrel at the time the loose
inhibiting powder exits the exit end of the barrel, of greater than about
8 feet.

7. The apparatus of claim 6, wherein the cloud, within less than half a
second from the loose inhibiting powder exiting the exit end of the
barrel, has a diameter that is greater than about three feet, where the
diameter is generally perpendicular to an axis of the barrel and distant
from a position of the exit end of the barrel at the time the loose
inhibiting powder exits the exit end.

8. The apparatus of claim 3, further comprising:a pusher element
positioned, prior to the propellant pressure being delivered into the
barrel, within the barrel proximate the powder inhibiting substance
between the powder inhibiting substance and the source of propellant
pressure such that the propellant pressure when delivered into the barrel
is applied against the pusher element such that the pusher element drives
the inhibiting powder out of the exit end of the barrel; anda seal
positioned, prior to the propellant pressure being delivered into the
barrel, proximate the powder inhibiting substance separating the powder
inhibiting substance from an environment exterior to the barrel.

9. The apparatus of claim 1, wherein the cloud, within less than half a
second from the inhibiting powder exiting the exit end of the barrel, has
a depth, from a position of the exit end of the barrel at a time the
inhibiting powder is propelled from the exit end, that is greater than
about five feet.

10. The apparatus of claim 1, wherein the cloud, within less than half a
second from the inhibiting powder exiting the exit end of the barrel, has
dimensions, distant from a position of the exit end of the barrel at a
time the inhibiting powder is propelled from the exit end, greater than
an average sized adult human.

11. The apparatus of claim 1, further comprising a membrane enclosing the
inhibiting powder prior to the propellant pressure being delivered into
the barrel, where the membrane ruptures, due to the force of the
propellant pressure delivered into the barrel, prior to the inhibiting
powder exiting the barrel releasing the inhibiting powder such that the
inhibiting powder contacts an interior surface of the barrel as the
inhibiting powder travels along a portion of a length of the barrel to be
propelled out of the barrel.

13. A launch system, comprising:a frame;a source of impulse pressure
cooperated with the frame;a barrel secured relative to the frame and
cooperated with the source of impulse pressure to receive a propellant
pressure from the source of impulse pressure;powder load positioned
within an interior of the barrel, the powder load comprising a powdered
inhibiting substance; anda burst diaphragm secured between the source of
the impulse pressure and the powder load, wherein the burst diaphragm
retains the impulse pressure from the source of impulse pressure until a
pressure of about equal to a burst threshold of the burst diaphragm such
that the burst diaphragm bursts releasing a propellant pressure into the
barrel to drive the powder load from the barrel in substantially an
aerosol form generating a powder cloud of powder load extending from a
exit end of the barrel.

14. The system of claim 13, further comprising:an actuator cooperated with
the source of impulse pressure, such that upon activation of the actuator
the source of impulse pressure releases the impulse pressure, and the
bursting of the burst diaphragm in response to impulse pressure launches,
substantially instantaneously, substantially all of the powder load in
response to a single actuation of the actuator.

15. The system of claim 14, wherein the powder cloud is configures to flow
around glasses to contact a target's eyes.

16. The system of claim 13, wherein the powder cloud is dispersed within
less than half a second from the single actuation of the actuator and has
dimensions larger than an adult human torso and is configured to flow
around obsticles to contact a target.

17. The system of claim 16, wherein the powder load further comprises one
or more inert powdered substances.

18. The system of claim 17, wherein the powdered inhibiting substance
comprises PAVA and the one or more inert powdered substances comprise
barium sulfate.

19. The system of claim 16, wherein the powdered inhibiting substance
comprises one or more capsaicinoids and nonivamide.

20. The system of claim 13, wherein the source of impulse pressure
comprises:a compressed gas cartridge storing compressed gas;a puncture
pin positioned relative to the compressed gas cartridge; andan expansion
chamber positioned between compress gas cartridge and the burst
diaphragm;where the burst diaphragm is positioned between the expansion
chamber and the powder load, such that upon the activation one of the
puncture pin and compressed gas cartridge is moved relative to the other
such that the puncture pin punctures the compressed gas cartridge
releasing the compressed gas into the expansion chamber resulting in the
increasing pressure applied to the burst diaphragm to burst the burst
diaphragm releasing the compressed gas to expel the powder load from the
barrel creating the powdered cloud.

21. The system of claim 13, wherein the burst diaphragm is configured to
rupture and resulting in a burst opening having dimensions such that the
retained impulse pressures is substantially instantaneously released into
the barrel providing the propellant pressure to drive the powder load
from the barrel in generating the powder cloud.

22. The system of claim 13, wherein the bursting of the burst diaphragm
generates an audible retort that is readily heard by a human at a
distances of greater than 20 feet.

23. A method of providing an individual with protection, the method
comprising:activating, in response to an actuation, a source of impulse
pressure;launching loose powder from a launch system; andgenerating a
powder cloud comprising the loose powder that has dimensions larger than
a human torso.

Description:

PRIORITY CLAIM

[0001]This application claims the benefit of U.S. Provisional Application
No. 60/973,447, filed Sep. 18, 2007, entitled NON-LETHAL IRRITANT POWDER
CLOUD LOADS FOR PERSONAL DEFENSE LAUNCHERS, which is incorporated herein
by reference in its entirety; and this application is a continuation of
International Application No. PCT/US08/76739, filed Sep. 17, 2008,
entitled SYSTEMS, METHODS AND APPARATUS FOR USE IN DISTRIBUTING IRRITANT
POWDER, which claims the benefit of U.S. Provisional Application No.
60/973,447, filed Sep. 18, 2007, entitled NON-LETHAL IRRITANT POWDER
CLOUD LOADS FOR PERSONAL DEFENSE LAUNCHERS, where International
Application No. PCT/US08/76739 is also incorporated herein by reference
in its entirety

FIELD OF THE INVENTION

[0002]The present invention relates generally to irritant powders, and
more particularly to methods and systems of dispersing irritant powders.

BACKGROUND

[0003]For several decades, Law Enforcement agencies have used various
non-lethal weapons to gain control of suspects, quell riots, save
hostages, and the like. Many of these non-lethal weapons typically
require a large launcher platform such as a shotgun, rifle or pistol to
deploy projectiles. These generally large platforms can make the use of
these launchers cumbersome in some circumstances.

[0004]To date, other than pepper spray, the general public typically has
not had access to a simple, low cost, non-lethal projectile launcher.
Further, there are generally no non-lethal projectile launchers that are
easily carried and used for personal defense at home, in the car or when
on foot.

SUMMARY OF THE EMBODIMENTS

[0005]The present invention advantageously addresses the needs above as
well as other needs through the provision of the method, apparatus, and
system for use in launching loose powder to generate a powdered cloud.
Some embodiments provide apparatuses for use in launching an inhibiting
powder. These embodiments comprise a source of impulse pressure that
induces a propellant pressure; a barrel cooperated with the source of
impulse pressure to receive the propellant pressure; inhibiting powder
positioned within an interior of the barrel; a burst diaphragm secured
between the source of the impulse pressure and the inhibiting powder; and
an actuator that activates the source of impulse pressure to deliver an
expanding gas producing an increasing pressure that is applied to the
burst diaphragm where the burst diaphragm bursts when the applied
increasing pressure exceeding a burst threshold of the burst diaphragm,
where the bursting of the burst diaphragm results in a release of the
propellant pressure into the barrel to drive the inhibiting powder from
the barrel in substantially an aerosol form generating a cloud of
inhibiting powder extending from an exit end of the barrel and out a
distance from the exit end of the barrel.

[0006]Other embodiments provide launch systems. At least some of these
launch systems comprise a frame; a source of impulse pressure cooperated
with the frame; a barrel secured relative to the frame and cooperated
with the source of impulse pressure to receive a propellant pressure from
the source of impulse pressure; powder load positioned within an interior
of the barrel, the powder load comprising a powdered inhibiting
substance; a burst diaphragm secured between the source of the impulse
pressure and the powder load, wherein the burst diaphragm retains the
impulse pressure from the source of impulse pressure until a pressure of
about equal to a burst threshold of the burst diaphragm such that the
burst diaphragm bursts releasing a propellant pressure into the barrel to
drive the powder load from the barrel in substantially an aerosol form
generating a powder cloud of powder load extending from a exit end of the
barrel.

[0007]Some embodiments provide methods of providing an individual with
protection. These methods activate, in response to an actuation, a source
of impulse pressure; launch loose powder from a launch system; and
generate a powder cloud comprising the loose powder that has dimensions
larger than a human torso.

[0008]A better understanding of the features and advantages of the present
invention will be obtained by reference to the following detailed
description of the invention and accompanying drawings which set forth an
illustrative embodiment in which the principles of the invention are
utilized.

BRIEF DESCRIPTION OF THE DRAWINGS

[0009]The above and other aspects, features and advantages of the present
invention will be more apparent from the following more particular
description thereof, presented in conjunction with the following drawings
wherein:

[0010]FIG. 1 depicts a simplified cross-sectional diagram of a launch
system according to some embodiments;

[0011]FIG. 2 shows a simplified cross-sectional view of a launch system,
similar to that of FIG. 1, with a membrane powder load comprising powder
retained within a membrane;

[0012]FIG. 3 depicts a simplified cross-sectional view of the launch
system, similar to the launch systems of FIGS. 1-2, with a powder load,
according to some embodiments, comprising the membrane powder load,
comprising powder retained within a membrane, and a projectile;

[0013]FIG. 4 depicts a simplified cross-sectional view of the launch
system, similar to the launch systems of FIGS. 1-2, with a powder load,
according to some embodiments, comprising powder and a projectile;

[0014]FIG. 5 depicts a simplified cross-sectional view of the launch
system, similar to the launch systems of FIGS. 1-2, with a powder load,
according to some embodiments, comprising powder and a projectile with a
divider or separator positioned between the powder and the projectile;

[0015]FIG. 6 depicts a simplified cross-sectional view of a launch system
according to some embodiments;

[0016]FIG. 7 depicts a simplified cross-sectional view of the frame of the
launch system of FIG. 6;

[0017]FIG. 8 depicts a simplified cross-sectional view of the barrel
assembly of the launch system of FIG. 6, according to some embodiments;

[0018]FIG. 9 depicts an enlarged view of a portion of the barrel assembly
of FIG. 8;

[0019]FIG. 10 show a simplified front view of a driver that can be
employed within the launch system depicted in FIGS. 6-7;

[0020]FIG. 11 show a simplified side view of the driver of FIG. 10 that
can be employed within the launch system depicted in FIGS. 6-7;

[0021]FIG. 12 depicts a simplified block diagram representation of a
powder cloud generated following the activation of a launch system
directed at a target;

[0022]FIGS. 13-14 depict a side view and a cross-sectional view,
respectively, of a launch system according to some embodiments FIG. 15
depicts a side view of a frame of the launch system depicted in FIGS.
13-14;

[0023]FIG. 16 depicts a simplified flow diagram of a process of assembling
a launch system, such as the launch systems depicted in or more of FIGS.
6-9 and 13-15; and

[0024]FIG. 17 depicts a simplified flow diagram of a process of activating
a launch system, such as one of launch systems depicted in FIGS. 6-9 and
13-15.

[0025]Corresponding reference characters indicate corresponding components
throughout the several views of the drawings. Skilled artisans will
appreciate that elements in the figures are illustrated for simplicity
and clarity and have not necessarily been drawn to scale. For example,
the dimensions of some of the elements in the figures may be exaggerated
relative to other elements to help to improve understanding of various
embodiments of the present invention. Also, common but well-understood
elements that are useful or necessary in a commercially feasible
embodiment are often not depicted in order to facilitate a less
obstructed view of these various embodiments of the present invention.

DETAILED DESCRIPTION

[0026]The present embodiments provide a launching system or device that
when activated expels a cloud of irritant powder towards a target, such
as a threatening target, as a means of non-lethal defense and/or for
subduing a target. This irritant cloud may have a distracting,
incapacitating and/or repelling effect on the target, be it a human or
animal. The irritant and distraction effects on the target may allow the
user to retreat to a safer location, get away from an attacker, or if
used by law enforcement or security personnel, subdue an individual for
capture and/or arrest. The concept of a small handheld powder launch
system can have many embodiments depending on the desired application.
The basic operation, however, is typically similar. When threatened by an
attacker or animal, for example, a user generally points or aims the
launch system in the threat direction and activates the system, for
example through a triggering mechanism, that results in the substantially
instantaneous deployment of an irritant powder payload cloud and/or a
non-lethal projectile towards the target.

[0027]There are many advantages to a device that deploys a simple blast of
irritant cloud from the muzzle of a compact self defense launching
system. In some embodiments, an irritant powder is launched towards the
target(s) that generates a cloud comprised at least partially of the
irritant powder with the intention that the cloud contacts the target(s)
directly, drifting on air currents towards the target(s), or just placing
a barrier irritant cloud between the user and the threat.

[0028]Therefore, the launching of a non-lethal powder, to generate a
powder irritant cloud, launched from a compact system provides many
advantages over conventional projectiles and/or other self defense
devices. For example, a powder irritant cloud does not require a precise
aim point on the target to affect the target such as with a projectile.
Further, unlike most conventional projectiles, the powder irritant cloud
can affect more than one threatening targets due to its relatively large
volume and ability to float on the air currents. A powder irritant cloud
can utilize a cross or back wind to further disperse its irritant towards
distant target(s). Unlike solid projectiles, a powder irritant cloud can
hang in the air and be an effective temporary barrier between the user
and the threat, and unlike pepper spray the powder cloud typically is
visible. Still further, devices that launch some projectiles, in some
areas of the United States and the World, may be considered a weapon,
e.g., launching a projectile carrying an inhibiting substances (such as
some projectiles described in U.S. Pat. Nos. 7,194,960; 6,546,874;
6,393,992; and 5,965,839, and Patent Application Publication Nos.
2005/0188886 and 2006/0027223, all of which are incorporated herein by
reference in their entirety) may be considered, in some areas of the
United States or the World, a chemical weapon, while the launching of a
loose powder that rapidly deploys into a cloud of inhibiting powder is
not considered a weapon and can be carried and/or used by the general
public and/or non-law enforcement individuals. Many other advantages are
provided by a launch system that launches loose powder to generate a
cloud of irritant powder as described below and will be apparent to those
skilled in the art.

[0029]The powder launch systems of the present embodiments can utilize any
number of different types of impulse energy sources to eject and/or
otherwise launch the loose powder, including impulse sources employed
within compact hand held devices. One or more of these different types of
impulse energy sources are used in launch systems to propel the
non-lethal powder loads of the present embodiments toward a target. For
example, the impulse energy source can be from a launch system using the
pressure impulse from a conventional firearm primer; an electrically
fired primer; a burning gas generator common to automobile airbag
technology; known gunpowder technology; by spark ignition of propane,
butane or other hydrocarbons; sources of compressed gas such canisters,
cylinders or cartridges of compressed gas (e.g., such as found in
refillable paintball gas cylinders); replaceable compressed gas
cartridges (e.g., cartridges such as used in air pistols and inflation
devices); and other such sources of impulse pressure and/or combinations
of sources of impulse pressure. For example, by utilizing disposable
and/or replaceable compressed gas cartridges filled with air, nitrogen,
carbon dioxide and/or other gases, some launch systems of the present
embodiments may be fabricated as a disposable (e.g., one time use) launch
system, and/or a portion of the launch system can be disposable and
replaced in an easily reloadable launch system.

[0030]As described above, the launch systems according to some embodiments
launch a loose powder that rapidly generates a cloud of powder extending
from the launch system. Launch systems and/or method of some
implementations can launch one load or multiple loads at a time or in
succession. A launch system may be capable of one or multiple launchings
through one or multiple barrels using various configurations. The launch
systems of some embodiments provide a source of gas impulse in a barreled
device. The choice of impulse gas energy can depend on many factors, such
as but not limited to, desired design, launch system size and/or weight,
desired powder cloud dispersion, size and/or weight of a launch load,
and/or other application factors. As introduced above, the powder loads
of the present embodiments can be utilized with many existing launchers,
and/or launch systems utilizing impulse pressure mechanisms (e.g.,
impulse gas) designed specifically to launch irritant, non-lethal powder
loads described herein.

[0031]FIG. 1 depicts a simplified cross-sectional diagram of a launch
system 100 according to some embodiments. The launching system includes a
frame or body 110 and a barrel assembly 112. Within the frame 110 is
mounted a source of impulse pressure 114. The barrel assembly 112
includes an entry orifice or opening 116, a barrel or barrel bore 118
with an exit end 120 opposite from the entry opening 116. In some
implementations, the frame 110 is removably mounted with the barrel
assembly 112 such that the entry opening 116 is cooperated with the
source of impulse pressure 114 allowing the impulse pressure to enter the
barrel 118, upon activation of an actuator (not shown), providing a
propellant pressure into the barrel 118. The removable mounting can
include threading 122, spring loaded pins, pin and grooves and
substantially any other such methods or combination of methods of
securing that, at least temporarily, fixes the frame 110 with the barrel
assembly 112 while the source of impulse pressure 114 generates and
directs the impulse pressure into the barrel 118.

[0032]A powder load 124 comprising powder that is unenclosed and is
positioned within the barrel 118. The powder load 124 is a loose powder
load in that at least a majority of the powder 124 upon being ejected
from the barrel 118 is loose and unenclosed to rapidly disperse into the
powder cloud extending from substantially the exit end 120 of the barrel
118 as described above and further below. The powder load 124 is
propelled, upon activation of the launch system 100, along the barrel 118
by the propulsion pressure and launched or ejected from the exit end 120
of the barrel assembly 112. In some implementations, a pusher or plunger
126 is positioned with the barrel 118 adjacent the powder load 124,
between the source of impulse pressure 114 and the powder load 124 such
that the propulsion force is directed against the pusher 126 to drive the
pusher along the barrel 118, which in turn pushes the powder load 124
along and out of the barrel assembly 112. Typically, the pusher 126 is
configured to establish a seal with the interior surface of the barrel
118 so that substantially all, and preferably all of the propulsion
pressure does not leak around the pusher 126 and is thus substantially
maintained behind the pusher 126. Further in some instances, the pusher
126 can be configured to provide equal distribution of the propulsion
pressure and/or focus the propulsion pressure, for example, by including
a rounded or tapered inlet, not shown, in the surface of the pushing that
receives the propulsion pressure. In other embodiments, however, the
pusher 126 is not included and the source of impulse pressure 114 directs
the propulsion pressure directly on the powder load 124.

[0033]The pusher 126 can be configured from substantially any relevant
material that can receive the propulsion pressure and travel along the
barrel 118 to drive the powder load 124 from the barrel assembly 112 at a
desired velocity. Further, it is desirable that the pusher 124 be
relatively light weight so that it is rapidly decelerates upon leaving
the barrel assembly 112 to fall to the ground, typically before reaching
a target. Additionally and/or alternatively, the pushing can be
configured to have a relatively large wind drag to aid in decelerating
the pusher upon exiting the barrel assembly 112. The pusher 126 can be
fabricated from any number of materials such as, but not limited to,
urethane foam, polymer foam, Styrofoam, paper, cardboard, plastic,
rubber, and/or other such similar materials or combinations of materials.

[0034]A seal or retaining member 128 can further be incorporated into the
barrel 118 in some implementations to retain the powder load 124 within
the barrel 118 and/or seal the powder load 124 within the barrel
providing a barrier between the powder load and exterior environmental
conditions. Typically, the seal 128 establishes a seal and/or is secured
within the barrel 118 to establish a seal with the interior surface of
the barrel 118 to protect the powder load 124 from the environment. The
seal 128 is shown in FIG. 1 being positioned within the barrel 118;
however, the seal can extend from the exterior of the barrel into the
barrel. Additionally or alternatively, a cap or other structure (not
shown) can be positioned on the exit end 120 of the barrel 118 and/or can
extend into the barrel to provide, in part, an additional seal to keep
foreign objects out of the barrel 118 and/or to provide an indication
that the launch system 100 has not been activated and that the barrel
assembly 112 contains a powder load 124 to be launched. Still other
structures can be incorporated with the exit end 120 of the barrel 112 in
those instances where a cap is not included to provide an indication of
whether the barrel assembly 112 has been previously activated to launch
the powder load.

[0035]The seal 128 (and/or cap when present) is also typically constructed
to rapidly decelerate upon being driven from the barrel assembly 112, and
can be fabricated from any number of materials such as, but not limited
to, paper, cardboard, urethane foam, polymer foam, Styrofoam, plastic,
rubber, wax, paraffin and/or other such similar materials or combinations
of materials. In some implementations the seal 128 is further secured,
such as glued to the interior surface of the barrel 118 to enhance and/or
ensure the seal and to retain the powder load 124. The glue can be
selected to readily break upon a sufficient pressure being applied by the
propulsion pressure allowing the seal 128 to detach from the interior
surface of the barrel 118 and be ejected from the barrel assembly 112.
The glue can be substantially any relevant glue, and in some instances is
waterproof or water resistant glue, such as but not limited to TiteBond
III® or other relevant waterproof and/or water resistant glues.
Similarly, a retaining member, such as an O-ring, may be employed to
maintain the positioning of the seal 128 (and/or pusher 126) within the
barrel 118. Additionally or alternatively, the seal 128 can be
constructed of a material, or be assembled with weakening features that
allow the seal to at least partially break apart when the propulsion
pressure drives the powder load 124 against the seal releasing the
powdered load to be driven along and out of the barrel assembly 112.

[0036]The powder load 124 comprises a powder that is propelled along the
barrel and ejected from the exit end 120 of the barrel assembly 112 in
substantially an aerosol to generate a powdered cloud extending from the
exit end 120 of the barrel toward a target, and in some instances about a
target when the target is within range. The powder load 124, in some
embodiments as depicted in FIG. 1, is free and loose and retained by the
pusher 126, the seal 128 and the interior surface of the barrel 118 such
that the powder load 124 is in contact with the interior surface of the
barrel 118 prior to and while being driven along the barrel assembly 112
to be ejected from the exit end 120 of the barrel 118. Typically, when
the barrel 118 is loaded with the pusher 126, and loose powder 124, the
loose powder is in an uncompressed state, and in some instances is not
packed or compressed when added to the barrel 118. In other embodiments,
however, the loose powder may be partially tapped or compressed, may be
inserted as a tablet, may be retained in a membrane or film prior to
activation of the launch system 100, and/or other such configurations
that are ejected from the barrel assembly 112 as loose powder in
substantially a loose, free and in some instances an aerosol state.

[0037]The powder load 124, as described above, typically includes one or
more powdered irritant and/or inhibiting substances. The irritating
and/or inhibiting powder can comprise one or more irritants such as, but
not limited to: one or more capsaicinoids; capsaicin; nonivamide; PAVA;
oleoresin capsaicinoid (OC); a pepper derived irritant; powdered tear gas
(CS or CN); and/or maloderants. The powder irritants may be naturally
occurring or synthetically produced. In some implementations, the powder
load 124 may be pure irritant powder or may be mixed with one or more
types of inert powders to achieve a desired concentration of irritant
effect on a target. Inert powders such as barium sulfate, baby powder,
cornstarch, talc, trisodium phosphate, silicon dioxide, flour, baking
powder, chalk, gypsum and/or similar non-toxic inert powders may be used
to achieve the desired irritant concentration and give more visibility to
the cloud. Relatively "heavy mass powders" such as barium sulfate or
other similar non-toxic heavy powders may be added to the powder mixture
to achieve a further launching or throw distance for the powder cloud in
some implementations. Visually colored, ultraviolet (UV) fluorescent
and/or other such marking powders may additionally or alternatively be
also be used or added to the mixture to achieve a marking function if
desired. Inert powder or inert powder mixture loads can also be used
without adding the irritant powder for the purpose of a training or
demonstration load that simulates the cloud performance of the irritant
powder loads. The powder load 124 can comprise powder, in some
implementations, as described in related U.S. Pat. Nos. 7,194,960;
6,546,874; 6,393,992; and 5,965,839, and Patent Application Publication
Nos. 2005/0188886; and 2006/0027223, all of which are incorporated herein
by reference in their entirety.

[0038]As described above, the powder load 124 is ejected from the exit end
120 of the barrel assembly 112 to generate the cloud of inhibiting
powder. To achieve the desired cloud in some instances the powdered load
124 is expelled from the barrel assembly 112 as an aerosol that rapidly
expands as it travels away from the barrel assembly 112 and launch system
100. The powder load configuration and/or particle sizes of the powder
load can affect the aerosolizing effect. In some embodiments, an average
particle size of at least the inhibiting powder portion of the powder
load 124 is less than about 200 microns, and typically is less than about
100 microns, for example, the particle sizes can be between 5-100
microns, where smaller irritant powder particles typically aids in the
hang time or time of suspension of the irritant powder particles and thus
the cloud. Other components of the powder load may have larger particle
sizes. For example, weighting particles may have larger sizes, where the
weighting particles aid in dispersing the launched inhibiting powder.

[0039]The aerosolizing effect is also, at least in part, dependent on the
amount of propulsion force applied and/or the speed at which the loose
powder is propelled from the barrel assembly 112. In some implementations
the propulsion force applied to the powder load 124 is greater than 200
psi, and typically greater than 400 psi. The amount of propulsion force
is further dependent on the size and/or weight of the powder load 124
(and pusher 126 and seal 128 when relevant). For example, with a powder
load 124 having a weight of about 5 grams, a propulsion force of over 700
psi can effectively launch the powder load, in some implementations, to
generate an expanding cloud that is greater than about 8 feet deep
extending from a position of the exit end 120 at the time of launch, and
with a width (generally perpendicular to the depth at about 8 feet) of at
least about 3 feet. Various cloud sizes, shapes and depths can be
obtained by changing the elements and parameters of the launch system
and/or load.

[0040]The powder load 124, typically, is a fine particle powdered
substance such that the particle sizes or grain are less than 1000
microns in diameter, and preferably less than 500 microns, more
preferably less than 250 microns, and in many instances less than 100
microns. It has been found that the generally the smaller the particle
diameter in a powdered load 124, the more effective the dispersal, and
typically the larger the volume of the dispersal, of the powder into a
cloud upon being launched from the launch system 100. In some instances,
the nature of the cloud produced is similar to, for example, a cloud that
is formed when clapping erasers together, only generally much larger in
volume. As will be seen, it is advantageous that the powder load 124
produce a fine cloud of the powder such that the cloud will be dispersed
on and about the target, such that the target inhales the substance,
and/or creates a relatively large suspended powder cloud barrier (e.g.,
larger than an adult human head, adult human torso or adult human body).

[0041]As described above, the powder load 124 can include an inhibiting
substance, and in some instances comprises a powdered oleoresin capsicum
powder or capsaicin powder that has a particle size of less than 500
microns, preferably less than 100 microns, and more preferably less than
20 microns, e.g. 5 to 10 microns in diameter. Thus, when such powder is
rapidly launch from a launch system 100 a cloud of finely powdered
substance 124 is produced that has a depth of at least about 6 feet, and
a width of at least 2 feet and preferably at least 3 feet in diameter.
This cloud advantageously "wafts" in the air for several seconds, for
example, more than 5 seconds and with some powder loads 124 more than 10
seconds before settling, allowing sufficient time for a target to inhale
the powdered substance, and maintain a suspended powder barrier allowing
a user to escape. Further, the amount of inhibiting substance and/or
portion of inhibiting powder within the powder load 124 can vary
depending on many factors. For example, the powder load 124 can contain
about 5% PAVA (Capsaicin TI, nonivamide) capsacinoids by weight, with
about 95% by weight of inert substances, such as barium sulfate and/or
weighting substance(s).

[0042]Still referring to FIG. 1, the frame 110 and/or barrel assembly 112
can be constructed of substantially any material or combinations of
materials that withstand the impulse and propulsion pressures induced by
the activation of the launch system 100. For example, the frame 110
and/or barrel assembly 112 can be fabricated from any number of materials
such as, but not limited to, plastic, metal, metal alloys and/or other
such similar materials or combinations of materials. In some
implementations, one or more components of the frame 110 and/or barrel
assembly 112 are formed from molded metal and/or plastic, such as
injection molded plastic and/or reinforced plastic (e.g., reinforced with
metal, fiberglass or other reinforcement materials). Additionally in some
embodiments, the barrel 118 may be opaque or partially opaque so that a
user can verify that the powder load 124 has not been launched.

[0043]Further, as introduced above, the frame 110 and barrel assembly 112
can be constructed to be detachable. This allows, in some embodiments,
the barrel assembly 112 to be pre-loaded with the pusher 126, powder load
124 and seal 128. Similarly, the launch system 110 can be constructed
such that the barrel is a replaceable and/or disposable portion that is
readily removed from the frame 110 allowing subsequent and/or alternative
barrels 112 loaded with powder loads 124 to be easily, and typically,
rapidly attached replacing a barrel from which the powder load 124 had
been launched, to replace a barrel that may have a defect, to replace a
barrel having a first type of powder load with a barrel having a
different type of powder load, and other such applications. The barrel
118 can be substantially any size that is capable of providing the rapid
expulsion of the loose powder load 124 while maintaining sufficient
pressure within the barrel to provide the desired propulsion force to
launch the loose powder load at sufficient velocity to induce the powder
cloud. For example, in some instances, the barrel has a length that is
less than 3 inches, and in some embodiments less than 2 inches greater
than a length of the pusher 126, powder load 124 and seal 128 (e.g., in
some embodiments, the length of the barrel 118 is less than 3 inches);
and with a diameter that is between about 0.25 inches to 2.0 inches, for
example about 0.7 inches.

[0044]As described above, powder loads of the present embodiments, such as
powder load 124, can be launched using any number of different types of
impulse energy sources. Again, the impulse energy source can be, for
example, from a launch system using the pressure impulse from a
conventional firearm primer; an electrically fired primer; a burning gas
generator common to automobile airbag technology; known gunpowder
technology; by spark ignition of propane, butane or other hydrocarbons;
sources of compressed gas such canisters or cartridges of compressed gas
(e.g., such as found in refillable paintball gas cylinders); replaceable
compressed gas cartridges (e.g., cartridges such as used in air pistols
and inflation devices); and other such sources of impulse pressure and/or
combinations of sources of impulse pressure.

[0045]In actuating the launch system 100, an actuator, such as a trigger
button, lever, trigger or other such actuator, activated to release a
spring mechanism, move a drive mechanism, actuate a valve, move a levered
wedge mechanism or other such method to release the impulse pressure. In
some embodiments that utilize compressed gas as at least a portion of the
impulse pressure, the actuator causes a compressed gas cartridge to be
forces into contact with a puncture pin; a valve to be opened; or uses
other release to affect a release of the compressed gas to be directed
into the barrel 118 and propel the powder load 124 from the barrel 118
(or shell cartridge containing the powder loads in some alternative
embodiments). The expanding gases released into the barrel 118 launch the
powder load 124 (or one or more various powder loads described below)
towards the intended target. Alternatively or additionally, in those
embodiments that utilize a primer, gunpowder and/or chemical gas
generator as the source of impulse pressure 114, then the actuator causes
an ignition of the primer, gunpowder, chemical gas generator, etc., which
produces hot gases that cause an impulse of expanding gas to propel the
powder load 124 from the barrel 118 (or cartridge shell).

[0046]FIG. 2 shows a simplified cross-sectional view of a launch system
200, similar to that of FIG. 1, with a membrane powder load 210
comprising powder 212 retained within a membrane 214. As introduced
above, in some implementations the powder load 212 is retained within a
membrane or film prior to activation of the launch system 100. The
membrane 214 is typically relatively thin and easily ruptured, and can be
constructed of substantially any relevant material or combinations of
materials such as, but not limited to, plastic, plastic wrap, paper, wax
paper, foam, wax and/or other such similar materials or combinations of
materials. Typically, the force applied by the pusher 126, in response to
the impulse pressure, against the membrane powder load 210 (as well as
the force of the membrane powder load 210 against the seal 128) readily
breaks the membrane 214 and the loose powder 212 is released from the
membrane such that the loose powder 212 is in contact with the interior
surface of the barrel 118 for a least a portion of the length of the
barrel 118 as the loose powder 212 travels along the barrel 118 toward
the exit end 120 of the barrel assembly 112 to be ejected from the barrel
assembly 112 in a loose, and in some instances an aerosol state. The
broken membrane is relatively light and typically has very poor
aerodynamics (particularly after being ruptured within the barrel 118),
and as such rapidly falls to the ground and typically does not strike the
intended target.

[0047]Some embodiments include one or more tabs 224, knife edges, pins or
the like positioned within the barrel 118 or at the exit end 120 of the
barrel assembly 112. The one or more tabs 224 cut, snag or otherwise
rupture the membrane as the membrane powder load 210 is propelled along
the barrel 118. In some instance multiple tabs provide multiple cuts
and/or effectively shred or partially shred the membrane 214.
Additionally or alternatively, a bar or cross-bar structure (not shown)
can be fixed within the barrel 118 or at the exit end 120 of the barrel
to rupture the membrane 214. Still further, in some instances the
membrane may be glued to the interior of the barrel, the interrior or a
portion of the interior of the barrel may rough or other such mechanisms
can be used to rupture the membrane.

[0048]The barrel 118 of the launch system 200 depicted in FIG. 2 is shown
with a length that is longer than the barrel of the launch system 100 of
FIG. 1. It is noted that the length of the barrel assembly 112 and/or
bore 118 can vary depending on payload weight, desired dispersion effect,
amount of propulsion forces, launch distance and other such factors. The
length of the barrel does not significantly alter the dispersion of the
powder load 124 in generating a powder cloud, for at least short or
relatively short distances of less than about 15 feet. The longer barrel,
however, may simplify assembly of varying powder launch loads and/or
embodiments of the launch system as described below.

[0049]FIG. 3 depicts a simplified cross-sectional view of the launch
system 300, similar to the launch systems 100, 200 of FIGS. 1-2, with a
powder load 310, according to some embodiments, comprising the membrane
powder load 210, comprising powder 212 retained within a membrane 214,
and a projectile 320. In the embodiment shown in FIG. 3, the powder load
310 is retained between a pusher 126 and a seal 128. In some embodiments,
the seal 128 is not included and instead the projectile 320 provides a
seal or at least a sufficient seal to launch the payloads. Additionally
or alternatively, an O-ring (not shown) or other similar structure can be
incorporated into the barrel 118 to retain the projectile 320 within the
barrel assembly 112 and/or to establish at least a sufficient
environmental seal between the O-ring and the projectile 320.

[0050]The projectile 320 includes a frangible shell 322 and a payload 324.
The payload 324 can include a powdered payload that can be that same as,
similar to or different from the powder load 124 and/or powder 212. In
other embodiments, the payload 324 is a liquid payload and/or a
combination of liquid and powder. The projectile 320 and/or payload 324
can be the same or similar to one or more of the projectiles and/or
payloads described in U.S. Pat. Nos. 7,194,960; 6,546,874; 6,393,992; and
5,965,839, and Patent Application Publication Nos. 2005/0188886; and
2006/0027223, all of which are incorporated herein by reference in their
entirety.

[0051]Upon activation of the actuator of the launch system 300, the source
of impulse pressure 114 delivers the propulsion force through the entry
opening 116 and into the barrel 118 to drive the loose powder 212 and
projectile 320 from the launch system 300. Again, the membrane 214
ruptures during launch, typically as a result of the propulsion pressure
and/or the force exerted on either side of the membrane powder load 210
by the pusher 126 and projectile 320. As described above with reference
to FIG. 2, one or more tabs 224 or other such structures can be
incorporated into the barrel 118 or at the exit end 120 to ensure that
the membrane 214 breaks prior to leaving the barrel 118.

[0052]The amount and/or weight of the powder load 310 can be substantially
the same as those described above. For example, the projectile 320 can
have a weight of about 3 grams while the membrane powder load 210 can
have a weight of about 2-3 grams, while employing a source of impulse
pressure 114 that is substantially the same as those for the embodiments
depicted in FIGS. 1-2 and described above. It is noted, however, that the
amount of propulsion force can vary depending on the size and/or weight
of the powder load 310, and in some instances the length of the barrel
118 between the projectile 320 and the exit end 120. In some embodiments,
the barrel 112 has a longer length when a projectile 320 is launched from
the launch system 300. The longer barrel length allows the projectile 320
to gain sufficient velocity when launched to have a desired launch
distance and/or provide a desired kinetic impact at the target (e.g.,
that results in pain to the target). Further in some implementations,
barrel 118 may include rifling that can induce rotation to the projectile
320, which in some implementations enhances stability and/or increases a
launch distance.

[0053]FIG. 4 depicts a simplified cross-sectional view of the launch
system 400, similar to the launch systems 100, 200, 300 of FIGS. 1-3,
with a powder load 410, according to some embodiments, comprising an
unenclosed and free powder 412 and a projectile 320 positioned within the
barrel 118. The powder load 410 is retained between a pusher 126 and a
seal 128. In some embodiments, the seal 128 is not included and instead
the projectile 320 or projectile and sealing structure (e.g., O-ring),
provides a seal or at least a sufficient seal to protect the loose powder
412 from the environment. The powder 412 is a loose powder load in that
at least a majority of the powder 412 when ejected from the barrel 118 is
loose and unenclosed to rapidly disperse into the powder cloud extending
from substantially the exit end 120 of the barrel 118 as described above
and further below. In some instances the powder 412 can be tapped or
lightly compressed while still being launched as loose powder. Upon
activation the powder load 410 is propelled from the barrel 118 such that
the projectile is launched while the powder 412 is ejected as a loose
powder establishing a powder cloud.

[0054]The amount and/or weight of the powder load 410 can be substantially
the same as those described above. For example, the projectile 320 can
have a weight of about 3 grams while the powder load 412 can have a
weight of about 2-3 grams, while employing a source of impulse pressure
114 that is substantially the same as those for the embodiments depicted
in FIGS. 1-2 and described above. It is noted, however, that the amount
of propulsion force can vary depending on the size and/or weight of the
powder load 410, and in some instances the length of the barrel 118
between the projectile 320 and the exit end 120. In some embodiments, the
barrel 112 has a longer length when a projectile 320 is launched from the
launch system 400. The longer barrel length allows the projectile to gain
sufficient velocity when launched to have a desired launch distance
and/or provide a desired kinetic impact at the target (e.g., that results
in pain to the target). Further in some implementations, barrel 118 may
include rifling that can induce rotation to the projectile 320, which in
some implementations enhances stability and/or increases a launch
distance.

[0055]FIG. 5 depicts a simplified cross-sectional view of the launch
system 500, similar to the launch systems 100, 200 of FIGS. 1-2, with a
powder load 510, according to some embodiments, comprising powder 512 and
a projectile 320 with a divider or separator 514 positioned between the
powder 512 and the projectile 320. The powder 512 is unbound and
unencased other than by the interior of the barrel 118, the pusher 126
and separator 514, and in some instances can be similar to the powders
124, 412 of FIGS. 1 and 4. The powder 512 is a loose powder load in that
at least a majority of the powder 512 when ejected from the barrel 118 is
loose and unbounded to rapidly disperse into the powder cloud extending
from substantially the exit end 120 of the barrel 118 as described above
and further below. The divider 514 retains the powder 512 and
substantially prevents the powder 512 from contacting the projectile 320,
which may in some instances avoid the powder 512 from being lodged
between the shell 322 of the projectile 320 and the interior surface of
the barrel 118. In some instances, the lodging of powder 512 between the
shell 322 of the projectile and the interior surface of the barrel 118
may jam the projectile within the barrel 118 and/or result in requiring
an increased propulsion pressure to launch the powder load 510. The
divider 514 can be constructed of substantially any number of materials
such as, but not limited to, urethane foam, polymer foam, Styrofoam,
paper, cardboard, plastic, rubber, wax, paraffin and/or other such
similar materials or combinations of materials. In some implementations,
the divider 514 is similar to the pusher 126 and/or seal 128. Further,
the divider can create a seal with the interior of the barrel 118 and/or
can be glued or otherwise secured with the interior of the barrel.

[0056]The powder 512 can be substantially similar to the powder 124 of
FIG. 1. The amount and/or weight of the powder 512 can, in some
embodiments, be between about 2-3 grams when the projectile 320 has a
weight of about 3 grams. The weight of the powder 512 and/or project can
vary depending on an amount of propulsion force that can be generated
from the source of impulse pressure 114, and/or a desired launch distance
of the projectile 320. As described with regard to at least FIG. 3, the
length of the barrel assembly 112 can also be increased in some
implementations to achieve a desired velocity of the projectile 320 at
the exit end 120 of the barrel. Additionally or alternatively, the
dimensions of the pusher 126, divider 514 and/or seal 128 can also be
adjusted.

[0057]FIG. 6 depicts a simplified cross-sectional view of a launch system
600 according to some embodiments. The launch system 600 includes a frame
610 and a barrel assembly 612. The frame 610 includes an actuator or
trigger mechanism 616 and a driver 618. The barrel assembly 612 comprises
a source of impulse pressure 620 and a barrel 622. Further, the source of
impulse pressure 620 includes a compressed gas cartridge, cylinder or the
like 624, a puncture pin 626, an expansion chamber 628 and a burst
diaphragm or disc 630. The barrel 622 includes an entry opening 632 and a
barrel bore 634. A load is incorporated into the barrel bore 634 and the
load can include, in some implementations, a pusher 640, powder payload
642 and a seal 644.

[0058]In some implementations the barrel assembly 612 is detachable from
the frame 610, and further in some embodiments the barrel assembly 612 is
replaceable such that upon activation of the launch system 600 and the
launching of the powder payload 642, the spent barrel assembly can be
detached and a new barrel assembly 612 can be secured with the frame 610.
Substantially any mechanism can be employed to secure the barrel assembly
612 with the frame 610. Some of these mechanisms can include, but are not
limited to, screw threading, pin and groove, one or more spring loaded
pins, latch(es) and other such methods.

[0059]FIG. 7 depicts a simplified cross-sectional view of the frame 610 of
the launch system 600 of FIG. 6. The frame 610 as introduced above
includes the trigger mechanism 616 and the driver 618. Additionally, the
frame 610 includes a barrel assembly receiving port 710 that receives and
secures a barrel assembly 612. In some implementations, the trigger
mechanism further includes a trigger or actuator lever 712 that is
pivotably secured with the frame 610 at a pivot 714, with a rivet, screw,
pin or other such mechanism. Further, the lever 712 is in contact with
and/or secured with the driver 618. A driver stop 716 is also included in
some implementations as described fully below.

[0060]FIG. 8 depicts a simplified cross-sectional view of the barrel
assembly 612, according to some embodiments, that can be utilized in the
launch system 600 of FIG. 6. FIG. 9 depicts an enlarged view of a portion
of the barrel assembly 612 of FIG. 8 showing the compressed gas cartridge
624, the puncture pin 626, the expansion chamber 628, burst diaphragm 630
and entry opening 632. Referring to FIGS. 6 and 8-9, in some embodiments
the barrel assembly 612 is assembled from a cartridge holder or housing
812 and the barrel 622 that are secured together with the burst diaphragm
630 positioned proximate an interface between the cartridge holder 812
and the barrel 622. The cartridge holder 812, in some implementations, is
secured with the barrel 622 through threading, gluing, tongue and groove,
welding and other relevant methods, or combinations of methods. For
example, the cartridge holder 812 can include threading 814 to be screwed
together with the barrel 622, and a further adhesive or glue can be
included, that in implementations may at least partially melt the
material of the cartridge holder and/or barrel to further secure, bond
and/or partially weld the components together. Securing the cartridge
holder 812 and barrel 622 maintains the relationship between the
cartridge holder 812 and the barrel during launching and can withstand
the pressures generated in launching the loose powder load 642 and/or a
projectile. In some implementations, for example, the cartridge holder
812 and the barrel 622 can be secured by applying glue (e.g., Instant
Krazy Glue®) that can be brushed onto threads 814 of one or both the
cartridge holder 812 and the barrel 622. In some instances the burst
diaphragm 630 is retained in position by clamping the burst diaphragm or
a frame or ring positioned with and/or secured with the burst diaphragm
between the cartridge holder 812 and the barrel 622. Alternatively, or
additionally, the burst diaphragm 630 is also glued or otherwise sealed
in place. For example, a glue, such as LOCTITE Superflex Clear RTV®)
can be applied on one or both sides of the burst diaphragm (e.g., on both
sides of a perimeter of the burst diaphragm 630 to help in preventing
leaks). Additionally in some implementations, the barrel assembly 612 is
has a cylindrical structure to take advantage of the inherent structural
strength to aid in withstanding the launch pressures.

[0061]The compressed gas cartridge 624 is slidably positioned within a
cartridge port or chamber 912 of the barrel assembly 612 that allows the
compressed gas cartridge 624 to slide, when driven by the driver 618,
from a first position separated from the puncture pin 626 to a second
position in contact with and punctured by the puncture pin 626. In some
implementations a cartridge seal 914 is positioned within the cartridge
port 912 proximate the puncture pin 626. The compressed gas cartridge 624
transitions from a first position when driven by the driver 618 to a
second position to be punctured by the puncture pin 626. Typically, the
compressed gas cartridge 624 is further in contact with the cartridge
seal 914 that establishes a seal relative to the compressed gas cartridge
and the puncture pin such that substantially all of the released gas is
directed into the expansion chamber 628, either through and/or around the
puncture pin 626. The cartridge seal 914 can be configured from
substantially any relevant mechanism, such as an O-ring, washer or other
such mechanism, and similarly can be constructed of substantially any
relevant material to establish the desired seal. In some implementations,
the cartridge seal 914 is part of a puncture pin assembly that further
contains the puncture pin 626 and allows the puncture pin to be secured
within the barrel assembly 612 relative to the cartridge seal 912. It is
noted that the launch system 600 is shown such that the driver 618 drives
the compressed gas cartridge 624 onto the puncture pin 626. In other
embodiments, however, the puncture pin 626 can be driven into the
compressed gas cartridge 624 to puncture the cartridge and release the
gas, or both can be driven toward the other.

[0062]A passage, conduit or other such tube 916 can be included in some
implementations that extends between the puncture pin 626 and the
expansion chamber 628 to carry the gas released from the compressed gas
cartridge 624 into the expansion chamber 628. The released gas from the
compressed gas cartridge can flow through and/or around the puncture pin
626 and into the expansion chamber.

[0063]The burst diaphragm 630 seals the expansion chamber 628 from the
entry opening 632 and the barrel bore 634. As compressed gas continues to
be released from the compressed gas cartridge 624, pressure builds within
the expansion chamber 628 and against the burst diaphragm 630. When the
pressure within the expansion chamber 628 exceeds a burst threshold of
the burst diaphragm, the burst diaphragm bursts or ruptures rapidly
releasing the gas from the expansion chamber 628, through the entry
opening 632 and into the barrel bore 634. The cross-sectional areas of
the burst diagraph 630 and entry opening 632 are relatively large
compared with the size of the puncture hole in the cartridge resulting
from being punctured by the puncture pin. Further, the burst opening that
results within the burst diaphragm as a result of bursting is also
relatively large compared to the puncture hole, and in some instances is
about the size of the entry opening 116 (e.g., in those instances where
the burst diaphragm ruptures into the entry opening 116). In some
implementations, the area of the burst opening and/or entry opening 116
is 5, 10 or more times the size of the puncture hole. Because of the
relatively large size of the burst opening through which the compressed
gas is released into the barrel bore 634, a relatively large amount of
compressed gas is rapidly released into the barrel bore 634 to provide a
greater propulsion pressure onto the pusher 640 and powder load 642 than
otherwise would be provided from the puncture hole alone. The rapidly
explosive rupturing of the burst diaphragm provides the relatively large
opening to effect the rapid release of the propulsion force. The launch
system can be configured such that a size of a resulting burst opening is
established or tuned depending desired cloud dimensions, a load weight,
burst diaphragm material and/or thickness, an amount of propulsion
pressure, an expected amount of impulse pressure and/or other such
factors. Additionally, in some implementations the rupture of the burst
diaphragm results in an audible noise, report, retort and typically a
relatively loud pop or bang (typically that can be heard by a human at
more than 15 feet away, generally at more than 20 feet away and in some
instances more than 30 feet away), that can startle a target, may notify
others individuals in the area of the threat, and in some instance
induces a reaction by the target, such as taking an involuntary breath
that can cause the target to breath in some of the inhibiting powder of
the powder cloud 1210.

[0064]The size and/or volume of the expansion chamber 628 typically
depends on the compressed gas stored within the compressed gas cartridge
624, the volume of the compressed gas cartridge 624, a burst threshold of
the burst diaphragm or a combination of one or more of these. For
example, when the compressed gas cartridge 624 stores liquid carbon
dioxide (CO2), the volume of the expansion chamber 628 is typically
configured to be equal to or larger than the volume of the compressed gas
cartridge 624. This is due, at least, to the fact that as the carbon
dioxide bottled in liquid form is released there is a phase transition as
the liquid transitions and expands into a gaseous state. In some
implementations, the volume of the expansion chamber 628 is greater that
twice the volume of the compressed gas cartridge 624. For example in some
embodiments, the volume of the compressed gas cartridge is about 0.1
cubic inches, while the volume of expansion chamber 628 is about 0.5
cubic inches, providing about a 5-to-1 amplification of the volume with
the use of the expansion chamber 628 in cooperation with the burst
diaphragm 630. As another example, the volume of the expansion chamber
628 can be about 0.09 cubic inches, which can comprise two connected
cylinders, one that is about 0.382 inch in diameter and about 0.417
inches long, and the other that is about 0.627 inch in diameter and about
0.133 inches long. Other sources of compressed gas and/or types of gas
can be utilized as introduced above, such as air, nitrogen, other
relevant gases or combinations of gases. The expansion chamber 628 and/or
burst diaphragm 630 can be configured, selected and/or otherwise tuned to
one or more desired performance characteristics, such as but not limited
to desired cloud dimensions, a powder load weight, an amount of
propulsion pressure, an expected amount of impulse pressure, burst
diaphragm material and/or thickness, and/or other such factors.

[0065]The burst diaphragm 630 can be constructed of substantially any
relevant material capable of withstanding the desired pressures and
rupturing at about a desired pressure threshold. Further, the burst
diaphragm 630, in some embodiments, is a replaceable, disposable rupture
disk membrane secured between the barrel bore 634 and the expansion
chamber 628. When the gas pressure in the expansion chamber volume
reaches the stress limits of the membrane material of the burst
diaphragm, the burst diaphragm ruptures and the expanded gas is released
to accelerate the powder load 642 (and/or one or more projectiles) out of
barrel bore 634. The burst diaphragm 630 can be constructed of Mylar®,
polyethylene terephthalate (PET) Polyester film, paper, plastics, metal,
and substantially any other relevant material that maintains the
expanding gas within the expansion chamber allowing gas pressure to build
until a predefined and/or desired pressure is attained at which point the
burst disk ruptures. For example, in some implementations the burst
diaphragm 630 can be made of Mylar® with a thickness of more than 1.5
mm, for example, 3 mm, or other such thickness to provide a burst
threshold at a desired level, and/or include structural weakening
features.

[0066]The burst diaphragm 630 may rupture by exceeding the stress limit of
the material, alternatively by coming in contact with a sharp device
within the barrel assembly 612 that causes the burst diaphragm to
puncture releasing the built-up gas, and/or by breaking a seal or other
means of rupturing the burst diaphragm. The burst diaphragm 630, in some
implementations, is scored to control or change the pressure at which the
burst diaphragm bursts. The scoring can be in substantially any
configuration to establish weakening points that allow, in some
implementations, more precise and consistent bursting at desired pressure
thresholds. Additionally and/or alternatively, the burst diaphragm 630
under pressure may be designed to burst using other methods such as:
mechanical cutting or piercing of the burst diaphragm; using heated coils
or electrical arcs to create or melt a weak section or an initial pin or
small hole in the burst diaphragm; or other methods of aiding rupturing
the diaphragm material. Typically, the burst diaphragms have consistent
burst thresholds providing consistent operation of the launch system 600
between launches (e.g., by replacing a spent barrel assembly 612 with a
new, loaded barrel assembly). Other embodiments of the launch system 600
may employ one or more of a mechanical valve that opens; a fixed
diaphragm that opens by moving, folding and the like without rupture
(e.g., using magnets that release at defined pressures); a friction held
or other types of gas plug; and/or other relevant types of gas retainer
design methods that can be made to move or open to allow gas flow. The
burst diaphragm 630, valve and/or gas plug at least in part allows
sufficient gas pressure and volume to buildup, and once the burst
diaphragm ruptures (or is otherwise released) the gas enters the barrel
bore 634 providing a propulsion force on the pusher 640 to propel the
powder load 642 from the barrel bore 634 creating the desired powder
cloud.

[0067]Referring back to FIGS. 6-7, the driver 618 can be substantially any
mechanism that responds to the actuation lever 712 to drive the
compressed gas cartridge 624 onto the puncture pin 626, or that drives
the puncture pin into the compressed gas cartridge. In some
implementations, the driver 618 transfers the motion of the actuation
lever 712 to the compressed gas cartridge 624 or puncture pin 626. For
example, as the lever 712 is actuated by an external force (represented
by the arrow labeled 720) the lever pivots at the pivot 714 and activates
the driver 618 to move the compressed gas cartridge 624 to be punctured
by the puncture pin 626. In some embodiments, the frame 610 further
includes a driver stop 716. The driver stop is cooperated with the driver
618 to maintain a positioning of the driver 618, at least prior to
activation.

[0068]FIGS. 10-11 show a simplified front view and a side view,
respectively, of a driver 1010 that can be employed for the driver 618 of
the launch system 600 of FIGS. 6-7. The driver 1010 includes a fixed
fulcrum arm pair 1012 and a lever fulcrum arm 1014. As shown in FIG. 11,
the fixed fulcrum arm pair 1012 can include two fulcrum arms 1020-1021
that are positioned on either side of the lever fulcrum arm 1014. It will
be apparent to those skilled in the art that other configurations can be
utilized. For example, the fixed fulcrum arm pair 1012 or lever fulcrum
arm 1014 can be replaced by a single, generally Y-shaped fulcrum arm. The
fixed fulcrum arm pair 1012 is secured with the frame 610 at a first
pivot 1024, and pivots relative to the frame 610 at the pivot 1024.
Further, the fixed fulcrum arm pair 1012 is secured with the lever
fulcrum arm 1014 at a second pivot 1026. Similarly, the lever fulcrum arm
1014 is pivotably secured with the actuator lever 712 at a third pivot
1028.

[0069]Upon activation of the actuation lever 712, the lever fulcrum arm
1014 is moved toward the fixed fulcrum arm pair 1012. As the lever
fulcrum arm 1014 is moved toward the fixed fulcrum arm pair 1012 both the
lever fulcrum arm 1014 and the fixed fulcrum arm pair 1012 move, at the
second pivot 1026, generally laterally and/or perpendicular to the force
applied by the lever fulcrum arm at pivot 1028. This lateral movement of
the lever fulcrum arm 1014 and the fixed fulcrum arm pair 1012 results in
a relatively large lateral movement for a relatively small vertical
motion.

[0070]As introduced above, some embodiments include a driver stop 716. The
driver stop 716 can maintain a positioning of the lever fulcrum arm 1014
relative to the fixed fulcrum arm pair 1012. Particularly, the driver
stop 716 prevents the lever fulcrum arm 1014 from being aligned with the
fixed fulcrum arm pair 1012, and maintains an angle 1030 between the
lever fulcrum arm 1014 and the fixed fulcrum arm pair 1012. This angle
1030 ensures that the driver 618 will bend at the second pivot 1026 and
induce the lateral motion to drive the compressed gas cartridge 624 onto
the puncture pin 626 (or the puncture pin into the compressed gas
cartridge). In some implementations, the actuation lever 712 in
cooperation with the driver 618 can induce 40 lbs or more of pressure
that can be exerted on the compressed gas cartridge 624 to puncture the
cartridge.

[0071]As described above, the launch systems 100, 600 rapidly launch loose
powder, e.g., loose powder 124 (and in some instances a projectile, e.g.,
projectile 320) generating a powder cloud. FIG. 12 depicts a simplified
block diagram representation of a powder cloud 1210 generated following
the activation, by a user 1214, of a launch system 1212 (which can be
similar, for example, to the launch systems 100, 600 of FIGS. 1-9)
directed at a target 1216. The use of the expansion chamber 628 and the
burst diaphragm 630 allows the launch system 1212 to rapidly apply the
propulsion pressure to the pusher 126, 640. As described above, the burst
diaphragm 630 fails at a burst threshold providing a relatively large
hole through which the compress gas rapidly, and in some instances
substantially instantaneously exits. The built up pressure within the
expansion chamber 628 can be substantially any relevant pressure to
achieve the desired propulsion pressure. In some implementations, burst
threshold can be 600 psi or more. For example, when using compressed gas
cartridge 624 holding compressed carbon dioxide at about 800 psi, the
burst diaphragm 630 can be selected to have a rupture threshold of less
than 800 psi, and the expansion chamber can be configured with a volume
that allows the compressed carbon dioxide to be released from the
compressed gas cartridge 624, phase transition to the gaseous state, and
generate a sufficient pressure within the expansion chamber 628 and
against the burst diaphragm 630 to rupture the burst diaphragm providing
a rapid release of the gas to drive the pusher 640 to propel
substantially all, and preferably, the entire power load 642 from the
barrel 622. As a result, the loose powder 642 is launched from the barrel
622 in less than one second, typically less than one half a second, and
more typically in less than hundreds of milliseconds from the time the
compressed gas cartridge 624 is punctured.

[0072]Further, the propulsion pressure when released from the expansion
chamber 628 is sufficient to launch the loose powder load 642 at a
sufficient velocity to generate the cloud 1210 of powder (which in some
embodiments as described above, include inhibiting powder) establishing a
barrier between the user 1214 and the target 1216. Further, the rapid
launch of the loose powder load 642 results in the rapid dispersion of
the powder cloud 1210 that has a depth 1218, measured from a exit end of
the barrel at the time of launch and an advancing front end 1220 of the
cloud, within less than a second, typically less than one half a second,
and some implementations within less than tens of milliseconds from the
time the compressed gas cartridge 624 is punctured. For example, some
embodiments establish an propulsion pressure of between about 600 and 800
psi resulting in a rupture of the burst diaphragm 630 and propel the
loose powder 642 from the launcher 610 at a velocity of greater than 100
feet per second, typically greater than 200 feet per second, and in some
instance at about 300 feet per second or more, to produce a powder cloud
1210 that has a depth 1218 (measured generally parallel with the length
of the barrel 622 at the time of launch) of more than 5 feet, and
typically more than 8 feet, and in some instances as much as 14 feet or
more, in less than one half a second from the time the compressed gas
cartridge 624 is punctured; additionally, the loose powder 642 exits the
exit end 120 of the barrel 622 at an angle 1222 relative to an axis of
the barrel length that is generally greater than about 10 degrees, and in
some instances greater than 20 degrees such that a width of the powder
cloud 1210 is greater than about 2 feet, and typically greater than about
3 feet when measured at a depth 1220 of at least 8 feet. The launch
system can be configured and/or tuned to achieve a desired exit velocity
depending on one or combinations of the many variables, such as but not
limited to, source gas pressure and volume, expansion chamber and volume,
burst disk material and thickness, entry opening and/or burst diaphragm
retaining ring hole, barrel length, payload weight and other such factors
and/or combinations of factors.

[0073]As the powder cloud 1210 advances it envelops the target 1216 in
those instances where the target 1216 is within at least the depth range
of the powder cloud and/or should the target try to advance toward the
user 1214. The inhibiting powder within the powder cloud 1210 rapidly
contacts and affects the target 1216 inhibiting and in some instances
effectively disabling the target 1216. Further, because the launch
systems 100, 600 launch the loose powder load 124, 642 that generates the
large powder cloud 1210, that is typically about as large as or larger
than an average adult human, the user 1214 is not required to have good
aim or directly hit the target 1216 with a projectile and still achieve
effective deterrent results. Instead, the powder cloud 1210 establishes a
barrier between the user and the target 1216 and in some instances
surrounds and/or envelopes the target 1216. This powder cloud 1210
further "wafts" in the air for several seconds, for example, for more
than 6 seconds and in some instances as much as 10 seconds or more before
settling, allowing sufficient time for the target 1216 to inhale the
powdered substance and/or get irritant powder in the target's eyes, as
well as allow the user 1214 sufficient time to flee with the barrier of
the powder cloud 1210 protecting the user's retreat.

[0074]This is in contrast to many non-lethal deterrent systems in that
many non-lethal deterrent systems require the user to be directly hit
with a projectile or stream of liquid. Further, some deterrent systems,
such as canisters of pepper spay, additionally require relatively long
periods of time of, in some instances, 10 seconds or more to empty the
canister of the inhibiting substance. Still further, many deterrent
systems not only require a direct hit of the target but further require
the inhibiting substance to be a directed stream into the targets eyes,
which can be particularly difficult in stressful situations where an
assailant is rapidly approaching and trying to prevent the inhibiting
substance from hitting his/her eyes.

[0075]The rapidly dispersed powder cloud 1210 does not require a direct
hit of a projectile or require that the powder be specifically directed
into the target's eyes. Instead, the powder envelops the target 1216 and
enters the target's eyes (even passing around glasses), mouth and nasal
cavity to inhibit the target 1216. Further, the powder cloud can pass
around and/or through barriers to content a target, including passing
around obsticles that a target might be hiding behind, passing around
glasses and other obsticles, obstructions and/or barriers.

[0076]Some embodiments, as described above can additionally include a
projectile 320. These embodiments additionally allow the user to launch
that projectile 320, which will typically travel a further distance that
the powder cloud 1210. Additionally, the impact of the projectile 320
provides a kinetic impact on the target that can result in pain to the
target.

[0077]The powder loads 124, 624 and/or payload 324 of a projectile 320, as
described above, can comprise any of the following substances: an
inhibiting substance such as oleoresin capsicum (also referred to as
"OC"), capsaicin, nonivamide (i.e., one or more of the hottest active
ingredients or capsaicinoids within oleoresin capsicum), tear gas (e.g.,
CS or CN), PAVA and other such natural and synthetic inhibiting
substances; a marking or tagging substance, such as a colored dye, UV
dye, IR dye or other such marking substance; a malodorant; and/or an
inert substance, such as barium sulfate, baby powder, corn starch, talcum
or other such inert substances; weighting substances; and/or any
combination thereof. For example, the powder 124, 624 and/or payload 324
in accordance with some embodiments can include a combination of
oleoresin capsicum and barium sulfate (or alternatively, a combination of
PAVA (nonivamide) and barium sulfate and/or other such inert powders
and/or weighting particles), at a desired ratio(s). Alternatively, a
combination of PAVA and/or oleoresin capsicum, and/or other inhibiting
substance, and a colored dye, malodorant and/or other marking substance,
may be employed to simultaneously incapacitate the target and mark the
target for later identification. In some embodiments a marking substance,
a chemical marker or chemical fingerprinted paint, such as produced by
Yellow Jacket, Inc. of California, can be used which effectively leaves a
chemical ID or chemical fingerprint on the target, which can be used by
the police to verify a person was struck by a non-lethal projectile. As
such, the chemical marker can include a chemical ID, identifying the
batch of the marker, that is formulated into the marker during
manufacture. For example, a fleck of the chemical marker found on a
suspect two weeks after being impacted with the chemical marker, can be
chemically identified and traced to launch system 100; thus, the suspect
may be linked to a crime scene by the chemical marker. In yet other
alternatives, it may be desirable to employ only a marking substance or
only an inert substance, such as barium sulfate or talcum, as the powder
load 124, such as when the launch system 100, 600 is being used for
training purposes. Similarly, any projectile 320 can be filled with an
inhibiting powder or liquid, inert powder or liquid, and/or could be
empty.

[0078]In some embodiments, the projectile 320 includes the shell 322, for
example, a spherical capsule (although other shapes of projectile bodies
may be used) separable into two about equal halves (e.g. a first part and
a second part), wherein the halves contain a powdered impairing substance
sufficient in amount so that the shell 322 is about or greater than 50%
full and preferably between about 60% and 99% full, for example, from
between 75% and 95%, for example, about 90% filled with a powdered
substance 324 and wherein, to facilitate manufacture of the projectile
320, the powdered substance 324 within each half is compressed into a
ball, tablet, mount and placed in one half and sealed with the other
half. Alternatively, the powder(s) 324 could be compressed into each
separate half and retained therein by a thin membrane, for example a
paper foil, which contacts the inhibiting substance during assembly of
the projectile 320. In this embodiment, the thin membrane is sufficiently
strong to retain the desired substance 324 within the shell 322 as it is
manufactured or assembled, yet frangible enough to readily rupture
subsequent to sealing of the shell 322 and prior to, or at least
simultaneously with, impact with the target.

[0079]The powder load 124 and/or payload 324 of the projectile 320 may,
for example, contain at least 0.5% inhibiting substances (such as PAVA,
nonivamide (from natural or pharmaceutically and/or synthetically
produced sources) or oleoresin capsicum), e.g., between 1% and 30%, e.g.,
between 5% and 20%, with a remainder of the powder load 124 (or payload
324) being either an inert substance or a marking substance or a
different inhibiting substance, such as tear gas powder or a powder
malodorant. Alternatively, the powder load 124 and/or payload 324 may,
for example, comprise at least 0.1% capsaicin (which is an active
ingredient within oleoresin capsicum in either natural form or
pharmaceutical produced form), and preferably at least 0.5% capsaicin
with the remainder of the powder load 124 and/or payload 324 as either a
marking substance, an inert substance, and/or a malodorant. Similarly,
more than one inhibiting substance may be combined to provide a total of
at least 0.1% to about 30% or more of inhibiting substances (e.g.,
depending on the target to be impacted, such as a higher percentage may
be employed for impacting large animals).

[0080]In some variations, the powder load 124 and/or payload 324 may
include fragments of solid material to enhance dispersion of the loose
powder load 124 and/or payload 324. For example, crushed walnut shells,
rice, wood shavings, metal particles, such as metal powder or metal
particles, or the like may be added to the powder to help carry the
powder away from the launch system 100 and/or a point of rupture of the
projectile 320 against a target. The solid material, having a greater
density and mass than the powder load 124 (e.g., of inhibiting substance,
inert substance and/or marking substance) tends to project further from
the launch system 100, thereby facilitating dispersion of the loose
powder load 124 as it is carried by the solid material.

[0081]In further variations, a visible marking agent, a covert UV or IR
visible dye, malodorant, or other taggant can be added to the powder load
124 and/or payload 324 of the projectile 320 in order to provide a
mechanism for identifying the target at a later time. This feature of
this variation may be particularly useful in law enforcement or military
applications, where evidence gathering may be enhanced if the target can
be marked. By combining a marking agent with an inhibiting substance a
significant synergism is achieved. In another aspect, marking can be
effected by bruising of the target due to the kinetic impact of the
projectile 320 against the target.

[0082]In some embodiments of a marking substance, the projectile shell
322, e.g., capsule, may contain a chemical compound that has a
particularly offensive odor, also referred to as a malodorant. In use,
the projectile 320 can be launched at a suspect, such that the suspect
will have an unwelcome odor on his or her person. Such odor will
effectively "mark" the person. Additionally, a projectile 320 containing
a malodorant as at least part of the payload 324 may be used to repel or
keep persons away from a particular area. An area impacted by one or more
projectiles 320 will typically smell so offensive that it will keep
others from coming near the smell. The malodorant has applications in
crowd dispersal and crowd control, as well. On example of a malodorant
that has a particularly offensive odor is called "Dragons Breath" which
is an organic sulfur compound produced by DeNovo Industries, of The
Woodlands, Tex. In variations of this embodiment, a projectile 320 can
include as the payload 320, or at least part of the payload, a glass
capsule contained within the projectile shell 322. The glass capsule
seals within itself certain malodorants, such as Dragons Breath and/or
other sulfur compounds, that have solvent properties that can eat through
a plastic variety projectile shell. The glass capsule within the
projectile body is ruptured upon impact of the projectile body, releasing
the malodorant. In further variations, the glass capsule is guided
centrally within the projectile with protrusions formed within the
projectile. These protrusions center the glass capsule within the
projectile capsule and additionally may provide pressure points to assist
in the fracturing of the glass capsule upon impact.

[0083]In yet a further variation, the payload 324 within the projectile
320 can include a powdered inhibiting substance combined with a liquid or
gas irritant, or other agent to be delivered. The liquid or gas, and the
powdered irritant can be carried in separate chambers, in for example,
separate halves of the projectile 320 using membranes described herein to
contain the powdered inhibiting substance and the other agent, keeping
them separated, if needed. If a liquid or gas is contained by one or both
of the membranes, such membranes can be made, for example out of plastic,
vinyl, rubber or the like. The projectile 320 can be similar to those
described at least in U.S. Pat. Nos. 7,194,960; 6,546,874; 6,393,992; and
5,965,839, and Patent Application Publication Nos. 2005/0188886, and
2006/0027223, all of which are incorporated herein by reference in their
entirety.

[0084]FIGS. 13 and 14 depict a side view and a cross-sectional view,
respectively, of a launch system 1300 according to some embodiments. The
launch system 1300 includes a frame 1310 and a barrel assembly 1312. FIG.
15 depicts a side view of the frame 1310 of the launch system 1300 of
FIGS. 13-14. Referring to FIGS. 13-15, the launch system 1300 further
includes a safety 1314, an actuator or trigger lever 1316, a driver 1418,
a driver stop 1414, and an actuator lever biasing member 1416 fixed with
the frame 1310. The barrel assembly comprises a source of impulse
pressure 1420 and a barrel 1422. Further, the source of impulse pressure
1420 comprises a compressed gas cartridge 1424, a puncture pin 1426, an
expansion chamber 1428 and a burst diaphragm 1430. The barrel 622
includes an entry opening 1432 and a barrel bore 1434. A load is
incorporated into the barrel bore 1434 and the load can include, in some
implementations, a pusher 1440, powder payload 1442 and a seal 1444.

[0085]The safety 1314 is slidably secured with the actuator lever 1316 and
extends, when in an active state to prevent activation of the launch
system 1300, through a hole 1326 of the frame 1310. In operation, a user
would slide the safety 1314 in a direction away from the exit end 1436 of
the barrel 1434, for example, by press the extended portion of the safety
1314 that extends through the hole 1326 of the frame 1310. The actuator
lever 1316 is further cooperated with the lever biasing member 1416 that
biases the actuator lever 1316 away from the frame 1310. Upon depression
of the actuator lever 1316, the lever biasing member 1416 compresses, the
actuator lever 1316 drives the driver 1418 into the compressed gas
cartridge 1426 to force the compressed gas cartridge onto the puncture
pin 1426. The punctured compressed gas cartridge 1424 releases compressed
gas through and/or around the puncture pin 1426 to enter the expansion
chamber 1428. In some implementations the expansion chamber 1428
comprises two cooperated sub-chambers (which in some instances are
connecting cylinders) 1450, 1452. For example, the volume of the
expansion chamber 628 can be about 0.1 cubic inches, where the first
cylindrical sub-chamber 1450 can have a diameter that is about 0.4 inch
and about 0.42 inches deep, and the second cylindrical sub-chamber 1452
can have a diameter of about 0.63 inch and a depth of about 0.14 inches.

[0086]Once the pressure within the expansion chamber exceeds a burst
threshold of the burst diaphragm 1430, the propulsion pressure rapidly
enters the barrel bore 1434 to drive the pusher 1440 that in turn drives
the powder 1442 from the barrel 1422. Some embodiments may further
include a site 1330 and/or laser site (not shown, but may be activated,
for example upon disengaging the safety 1314) to aid the user in aiming
the launch system 1300. Additionally, some embodiments may include a key
ring 1332, clip or other fastener on which keys or other devices can be
secured and/or that can provide for easy of carrying.

[0087]FIG. 16 depicts a simplified flow diagram of a process 1600 of
assembling a launch system, such as the launch system 600 or 1300 of
FIGS. 6-9 and 13-15, respectively. In step 1610 the driver 1418 is
positioned and secured within a first half of the frame 1310. In step
1612, a safety 1314 and spring 1416 are secured with the actuator lever
1316. In step 1614, the actuator lever 1316 is positioned and pivotably
secured with the frame and the driver 1418, such that the spring 1416
cooperates with the frame 1310. In step 1616, a second half of the frame
is secured with the first half of the frame to maintain a positioning of
the actuator lever 1316 and driver 1418. In step 1618, a driver stop 1414
is positioned within the frame 1310 to prevent the fixed fulcrum arm pair
1012 and a lever fulcrum arm 1014 from being aligned and maintaining an
angle between the fixed fulcrum arm pair 1012 and a lever fulcrum arm
1014.

[0088]In step 1620 a puncture pin assembly, comprising the puncture pin
1426, a cartridge seal 914 and gas passage or tube 916 are cooperated. In
step 1622 the puncture pin assembly is secured within the cartridge
holder or housing 812. In step 1624 a burst diaphragm or disc 1430 is
positioned relative to the expansion chamber 1428 formed in the cartridge
holder 812. In some embodiments the burst diaphragm 1428 is glued or
otherwise secured and/or sealed with the cartridge holder 812. In step
1626 a barrel 1422 is secured with the cartridge holder 812, for example
screwed to the cartridge holder 812, with the entry opening 1432 being
positioned adjacent the burst diaphragm 1428. Again, in some embodiments,
the burst diaphragm 1428 is glued or otherwise secured and/or sealed with
the barrel 1422. Similarly in some implementations, the barrel is a
further glued with the cartridge holder 812.

[0089]In step 1630, a pusher 1440 is positioned within the barrel bore
1434 adjacent the entry opening 1432. In step 1632, the powder load 1442
is positioned within the barrel bore 1434 adjacent the pusher 1440. In
step 1634, a seal 1444 is secured within the barrel bore 1434 adjacent
the powder load 1442 sandwiching the unenclosed powder load between the
pusher 1440 and the seal 1444. Typically, the seal 1444 is inserted into
the barrel bore 1434 to a depth that will keep the powder load sealed in
the barrel. Additionally, the seal can further be glued or otherwise
sealed with the interior of the barrel bore in some embodiments. In step
1636 a compressed gas cartridge 1424 is inserted into the cartridge
holder 812 adjacent the cartridge seal 914 and the puncture pin 1426. In
some implementations, the assembled frame 1310 and the barrel assembly
1312 can be distributed separately. In other embodiments, an additional
step 1638 can be implemented where the frame 1310 and the barrel assembly
1312 are detachably secured to each other prior to distribution.

[0090]FIG. 17 depicts a simplified flow diagram of a process 1700 of
activating a launch system, such as one of launch systems 600 and 1300 of
FIGS. 6-9 and 13-15, respectively. In step 1710, the safety 1314, when
present, is disengaged. In step 1712 the launch system 1300 is generally
aimed at a target. In step 1714 the actuator lever 1316 is compressed,
depressed, squeezed or otherwise activated launching the load and
producing a large volume, visible cloud that can potentially inhibit a
target and/or provide a temporary inhibiting barrier. In some
embodiments, the process 1700 further includes step 1716, where the spent
barrel assembly is removed from the frame 1310 and a new barrel assembly
1312 is secured with the frame 1310. The process can terminate following
one of steps 1714 or 1716, or can return to step 1712 to again generally
aim the launch system for the deployment of a subsequent powder cloud
1210 to produce an additional powder cloud, effectively enlarging an
inhibiting barrier and/or adding to the previous cloud. As a result, the
process in some implementations activates, in response to an actuation, a
source of impulse pressure, launches loose powder from a launch system,
and generates a powder cloud comprising the loose powder that has
dimensions larger than a human torso. Typically, the loose powder
launched comprises inhibiting powder such that the powder cloud comprises
an inhibiting powder cloud.

[0091]For several decades, law enforcement agencies have used various
non-lethal weapons to gain control of suspects, quell riots, save
hostages, etc. Most of these non-lethal deployments utilize a rather
large launcher platform such as a shotgun, rifle or pistol to deploy the
projectiles. Further, to date, other than pepper spray, the general
public has not had access to a simple, low cost, non-lethal launcher that
could be easily carried and used for personal defense at home, in the car
or when on foot. The present embodiments provide low cost, compact
non-lethal personal defense launch systems that can be quickly deployed
and are effective on human and animal targets.

[0092]Many conventional launch systems utilize a projectile to affect the
target. For example, U.S. Pat. Nos. 7,194,960, 6,546,874, 6,393,992, and
5,965,839, incorporated herein by reference in their entirety, describe
many embodiments of frangible irritant powder filled projectiles, and
systems to launch such projectiles, that can affect targets utilizing
irritant powder clouds. These projectiles can be employed, as described
above, in some present embodiments.

[0093]Further, the present embodiments series of non-lethal powder loads
that can be launched by many different types of propulsion force or
pressure, and from many types of launchers, to be used against a target,
such as a threatening human or animal. Some of the launch systems are
that can be used to launch the loose powder loads are described here.
However, other launchers may be used, in some implementations. One or
more such compact launch device that could be utilized to launch the
loose or projectile-less irritant powder loads described herein include
one or more of the launching devices described in co-pending U.S. patent
application Ser. No. 11/129,230, filed May 12, 2005, to Vasel et al., and
entitled COMPACT PROJECTILE LAUNCHER.

[0094]At least some embodiments of the launch systems described herein
easily fit in a person's hand, a purse, pocket, glove box, and the like,
and are capable of launching the loose powder loads of powder irritants,
inert substances and/or marking substances. Further, these launch systems
expel a cloud of irritant powder towards a target, for example, as a
non-lethal defense. This irritant powder cloud typically has a
distracting, incapacitating and/or repelling effect on the target, be it
a human or animal, and in some instances is visible to a target further
inhibiting the target. The irritant and distraction effects on the target
may allow the user to retreat to a safer location, get away from an
attacker, or if used by law enforcement or security personnel, subdue an
individual for arrest. The propulsion force or pressure used to launch
the loose powder can include, but are not limited to, compressed gas,
firearm primers, gunpowder, burning hydrocarbons, chemical gas generators
or other means to accelerate these non-lethal irritant powder loads
towards the intended target(s). The innovative chemical loads described
herein can be directly loaded in barrels attached to these many launch
devices or loaded into cartridge shells that can be utilized in these or
other types of launchers.

[0095]While the invention herein disclosed has been described by means of
specific embodiments and applications thereof, numerous modifications and
variations could be made thereto by those skilled in the art without
departing from the scope of the invention set forth in the claims.